Panel support device

ABSTRACT

A device (1) for supporting a second panel in edge-to-edge relationship with a fixed panel, the support device (1) including a support plate (2), means (16) to permit the support plate (2) to be attached against the fixed panel, and means (4) for aligning the support plate (2) to overhang the fixed panel by an amount sufficient to support the second panel in the said relationship. The support plate may include a lip (5) to assist in placing the second panel on the support plate (2).

The present invention relates to a device for supporting a second panelin edge-to-edge relationship with a fixed panel. In particular, thepreferred embodiment of the invention relates to the device forassisting in the fixing of plasterboard and other sheet materials towalls, ceilings and partitions.

Walls, ceilings and partitions of many buildings incorporateplasterboard which leaves a smooth surface to the wall or ceiling.Plasterboard is much easier, quicker and less messy to erect than wetplaster is to apply. Since plasterboard is supplied in flat panels, aplasterboard fixer must cut the panel to a desired size and attach it tothe wall, ceiling or partition usually by means of screws or nails.

A framework is usually constructed to suit the dimensions of the panelso that the very edge of the fixed panel is supported by a frame memberto which the panel is fixed. The framework is usually made from metal orwood.

Plasterboard is quite brittle and will easily snap under its own weightif not supported correctly. Plasterboard panels are difficult to supportcorrectly whilst being offered up to the framework, particularly if thepanel is to be fixed to a ceiling. Furthermore, larger plasterboardpanels are difficult to handle since they are very heavy. A plasterboardfixer will offer the panel into the desired position using two hands togive adequate support. The plasterboard fixer must then remove one handto hold a hammer or screwdriver and the other hand to hold a nail orscrew in order that the panel may be fixed into position. During thefixing of the panel, the fixer will often use his head to support thepanel. The fixer may also use temporary propping e.g. a "deadman". Thishas the disadvantages that the panel may move during the attachmentleaving large or uneven gaps between adjacent panels, or the panel is indanger of damage due to incorrect support.

These disadvantages apply for example, to fixing plasterboard to walls,ceilings, soffits and partitions.

It is an object of the present invention to overcome or at least reducesome of the above disadvantages.

One aspect of the present invention is a device for supporting a secondpanel in edge to edge relationship with a previously fixed panel, thesupport device including a support plate, means to permit the supportplate to be attached against the fixed panel, and means for aligning thesupport plate to overhang the fixed panel by an amount sufficient tosupport the second panel to be fixed in the said relationship.

Preferably the support plate includes a lip to assist in placing thesecond panel, to be fixed, on the support plate.

Preferably also, the alignment means aligns the support plate so thatthe attachment permitting means is aligned with the fixed panel.

According to the preferred embodiment, the means to permit the supportplate to be attached against the fixed panel includes holes through thesupport plate.

It is an advantage to further include spacer means disposed on thesupport plate for spacing the support plate from the fixed panel.Normally the fixed panel is fixed against a support member and thespacer means spaces the support plate away from the fixed panel toassist in placing the second panel between the support plate and thesupport member.

Preferably the alignment means includes a flange extending from thesupport plate and disposed across the support plate to abut against theedge of the fixed panel.

In most situations, the edge of the fixed panel is fixed to a framemember of a framework so that the frame member overlaps the edge of thefixed panel and the device is attached directly to the frame memberthrough the fixed panel.

Preferably the alignment means aligns the support plate so that theattachment permitting means permits the device to be attached to theframework member.

The device may be provided with a handle or hook, preferably at one endthereof, for example, by bending part of the support plate into aU-shaped portion or by providing a separate handle attached to thesupport plate.

Further, the device may include means by which the device can be leveredfrom a fixed panel to which it is temporarily secured. Such means may beat one end of the device and may comprise an extension of the supportplate protruding therefrom. Alternatively, said lever means may beformed as an extension of a separately formed handle attached to andextending along the underside of the support plate, in which case, thatextension may be located at the end of the device remote from theU-shaped portion of the handle.

According to another embodiment, the support and alignment means areintegrally formed and/or the support plate and spacer means areintegrally formed.

The support device may be constructed from metal, plastics or othermaterial either in the form of sheets, extrusions or mouldings.

The support device is particularly useful when it is adapted forassisting in supporting plasterboard panels on walls or ceilings or forassisting in supporting partition panels.

Another aspect of the invention resides in a method of supporting asecond panel in edge to edge relationship with a fixed panel using adevice in accordance with the invention, which method comprisesattaching the support plate against the fixed panel, aligning thesupport plate to overhang the fixed panel by an amount sufficient tosupport the second panel in edge to edge relationship with the fixedpanel, and placing the second panel on the support plate, so that thesecond panel is supported by the device in edge to edge relationshipwith the fixed panel.

An embodiment of the present invention and some of its applications arenow described by way of example only with reference to the drawings inwhich:

FIG. 1 shows a perspective view of the device according to theinvention;

FIG. 2 shows an exploded view of the device according to the invention;

FIG. 3 shows a sectioned view of the device attached against a fixedpanel, and a panel to be supported being inserted into the device;

FIG. 4 shows a sectioned view of the device attached against the fixedpanel, and the second panel being offered into place;

FIG. 5 shows the second panel supported on a wall by two devices of thepresent invention;

FIG. 6 shows a panel supported on a sloping wall or soffit by devices ofthe present invention;

FIG. 7 shows two support devices supporting a second panel on a ceiling;

FIG. 8 shows two devices supporting a second panel upstanding from ahorizontal soffit;

FIG. 9 shows a second panel supported in a second layer with theframework constituted from a head track, a floor track and studs betweenthe tracks; and

FIG. 10 shows a perspective view of a modified form of the embodiment ofdevice shown in FIGS. 1 and 2.

Referring to FIGS. 1 and 2, the support device 1 includes a supportplate 2, a raised flange 4 extending from a face of the support plate 2and a spacer plate 3 which lies on the support plate 2 clamping theflange 4 into the position shown in FIG. 1. The raised flange 4 is partof an alignment plate 14 which is upturned along one edge to form anL-shaped section. The upturn forms the raised flange 4 which extendsperpendicularly away from the rest of the alignment plate 14. Thealignment plate 14 lies on the support plate 2 so that the raised flange4 projects outwardly from the surface of the support plate 2.

The support plate 2, alignment plate 14 and spacer plate 3 each have aseries of corresponding through-holes 6 which permit passage of a nail,screw or other fixing means therethrough.

The support plate 2 also includes a hook or handle 7 which enables thesupport device 1 to be hung on a belt and to be easily manipulated bythe user. Once the support device 1 has been attached, the hook 7 can beused to support tools such as a power screwdriver. The handle 7 may beformed by bending part of the support plate 2 into a U-shape, or byattaching a handle made separately from the support plate 2.

The spacer plate 3 and raised flange 4 lie on only a part of the supportplate 2. The rest of the support plate 2 has the function of assistingin supporting a second panel of plasterboard during attachment. Thesecond panel temporarily rests on the support plate 2, and to assist inplacing the edge of the second panel on to the support plate 2, thesupport plate 2 includes a lip 5 which is angled to present a deeperslot for insertion of the second panel.

The term "second panel" herein refers to the panel which is to be fixed.

The raised flange 4 has an added purpose in that when attached,measurements may be more accurately taken from the edge of a fixed panel12 since the tab of a tape measure may be inserted between the fixedpanel 12 and the raised flange 4.

FIG. 2 shows the construction of the support device very clearly. Inthis embodiment, the support plate 2, the alignment plate 14 and thespacer plate 3 are each made of sheet steel. However, it might becheaper and more effective to make the parts from other materials suchas plastics, or to make the whole or part of the device in the form ofan extrusion cut into lengths. The handle 7 could then be attachedseparately. The raised flange 4 is the part which is most easily damagedby being dropped, and this could be made to be replaceable.

Referring to FIGS. 3 and 4, the attachment of a second panel ofplasterboard to a wall, ceiling or partition 8 will be described.

Framework member 9 may be attached to a structure such as a ceiling orwall 8 to permit attachment of the plasterboard thereto. The frameworkmembers 9 are arranged to run parallel to each other, the distancebetween subsequent members 9 permitting each panel of plasterboard toabut at the approximate mid point of the frame member 9. Once a fixedpanel 12 of plasterboard has been attached, it is simple to use thesupport device of the present invention. The fixed panel 12 may be asmall `rip` panel which is easy to handle and takes very little time toput up. A fixed panel 12 is shown in FIGS. 3 and 4, attached to theframework member 9 by a screw 11, nail or other fixing means.

The support device 1 is placed against the fixed panel 12 with thespacer plate 3 lying flat against the fixed panel 12, and the raisedflange 4 abutting the edge of the fixed panel 12. The raised flange 4aligns the support device 1 so that the holes 6 line up with the framemember behind the fixed panel. The support device 1 is then nailed orscrewed against the fixed panel 12 by one or more nails or screws 10passing through the holes 6, through the fixed panel 12 and into theframe member 9. The support device 1 is therefore securely supported.

The second free panel of plasterboard 13 can then be supported by thesupport device 1. An edge of the second panel 13 is pushed across thelip 5 and on to the support plate 2 where the second panel 13 rests.Once the second panel 13 abuts against the raised flange, theplasterboard panel 13 is positioned as shown in FIG. 4 into its finalposition. The second panel 13 may then be screwed against the framemembers 9 and, once securely attached, the support device is unnailed orunscrewed and moved along ready to support the next successive panel.

One great advantage of the present invention is that the nails or screws10 pass through the plasterboard and into the frame members 9 veryeasily. The device takes only a few seconds to attach to the framemembers 9, and a few seconds to remove, but makes attachment of thepanel 13 much quicker and easier.

It is expected that this device will permit a fixing job to be completedin less time than the job would take using conventional methods.

The present invention will permit the use of larger plasterboard panelssince they are easier to support. Furthermore, as shown in FIG. 9, manywalls, ceilings and partitions require multiple layers of plasterboardto achieve a required specification. Since the raised flange does notextend from the support plate any further than the thickness of oneplasterboard panel, the only difference required is the use of longernails or screws 10 which must pass through two or more panels ofplasterboard before reaching the frame member 9.

In many situations it is advantageous to use more than one supportdevice so that the plasterboard panel is more securely supported by thesupport device. FIGS. 5 to 8 show examples of this.

In FIGS. 5 to 8 it is optional whether more than one support device 1 isused depending on the size of the panel and experience of the fixer.

Also in FIGS. 5 to 9, the holes 6 through the support device 1 areshown. In this embodiment four holes 6 are included, three of which arein a line so that a nail or screw 10 will pass through each hole 6,through the fixed plasterboard panel 12 and into the frame member 9behind. The fourth hole 6 provides support where the frame member 9 runsperpendicularly to the support device 1 and the outer two holes 6 of therow of three holes 6 will not engage with the frame member. In practice,it has been found that generally only one nail or screw 10 is requiredpassing through the most central hole 6a.

It might be expected that, once the support device 1 has been removed,the raised flange 4 will leave substantial gaps between panels. Theraised flange 4 should be of minimal thickness. The support device 1assists the fixer in aligning the panel more accurately thereby reducingthe possibility of large or uneven panel gaps.

This embodiment of the invention relates to temporary support of part ofa plasterboard panel, but may equally effectively be applied to mountingother types of panel or other sheet material.

FIG. 7 shows two devices 1 supporting a second panel 13 on a ceiling. Itis particularly useful to use two or more support devices in thissituation, particularly if the fixer is not experienced in fixingplasterboard. An experienced fixer might only require a device 1 locatedto support an end of the panel 13.

FIG. 8 shows a panel 13 being supported in an upstanding position fromthe ceiling. The upstanding position is frequently used where theceiling height increases e.g. leading to a skylight.

FIG. 9 shows a support device 1 supporting a panel 13 in edge to edgerelationship with a fixed panel 12 to form a second plasterboard layer.The plasterboard is fixed to a framework including a head track 15, afloor track 16 and stud 17.

Referring now to FIG. 10, here is shown a modified form of theembodiment of device described above in relation to FIGS. 1 and 2.

This modified device 1' comprises all the components of the embodimentof FIGS. 1 and 2, namely, the support plate 2, spacer plate 3, flange 4,lip 5, through-holes 6, 6a and a handle or hook 7. However, it alsocomprises an extension 2' of the support plate 2, which extension 2'protrudes from the end of the support plate 2 remote from the U-shapedportion of the hook or handle 7. If the hook or handle 7 is formedseparately from the support plate 2, then the extension 2' may be formedas part of the hook or handle 7, such that it protrudes from the end ofthe device 1' remote from the U-shaped portion of the handle or hook 7.In this case, the separate handle or hook 7 may be secured to theunderside of the support plate 2 so that it extends therealong.

In either case, the extension 2' provides means whereby the device 1'can be levered from the fixed panel 12 to which it is temporarilysecured, for example, by nail. Such levering can be effected by locatingthe claw portion of a claw hammer, or other suitable lever means,between the extension 2' and the fixed panel 12 to which the device 1'is temporarily secured and from which the extension 2' is slightlyspaced, and then levering the device 1' from that panel using the hammeror other lever means in a levering action.

I claim:
 1. A reusable support device for temporarily supporting asecond panel in a common plane and in edge-to-edge relationship with afixed panel, which panels are accessible from only one common sidethereof during use of the device, the device comprising:a support platehaving a first side and a second side; attachment permitting meansadapted to permit the support plate to be temporarily attached to thefixed panel from said one common side; spacer means disposed on thesupport plate and adapted to space the support plate from the fixedpanel; a flange upstanding and extending across the support platebetween said first and second sides, said flange adapted to abut an edgeof the fixed panel to align the support plate with respect to the fixedpanel so that said second side of the support plate extends beyond theedge of the fixed panel for supporting the second panel on the supportplate in a common plane with the fixed panel, and said flange adapted tobe abutted by an edge of the second panel such that the two panels arein edge-to-edge relationship with each other with the flange protrudingbetween the panels not more than the thickness of the panels; and a lipextending in an angle from said second side of the support plate forassisting in placing the second panel on the support plate, wherein thesupport plate is adapted to be detached from the fixed panel from saidone common side, for reuse of the device after the second panel has beensecured permanently by other means in said relationship with the fixedpanel.
 2. A reusable support device according to claim 1, wherein saidattachment permitting means includes holes through the support.
 3. Areusable support device according to claim 1, wherein the flange isadapted to align said attachment permitting means with the fixed panel.4. A reusable support device according to claim 1, wherein said spacermeans is adapted to space the support plate away from the fixed panelfor assisting in placing the second panel between the support plate anda support member to which the fixed panel is secured.
 5. A reusablesupport device according to claim 1, wherein the support plate isadapted to be attached through the fixed panel to a framework member towhich the fixed panel is secured and which overlaps the edge of thefixed panel.
 6. A reusable support device according to claim 5, whereinthe flange is adapted to align said attachment permitting means with theframework member.
 7. A reusable support device according to claim 1,wherein the support plate and flange are formed integrally.
 8. Areusable support device according to claim 1, wherein the support plateand said spacer means are formed integrally.
 9. A reusable supportdevice according to claim 1, including a handle for enabling the deviceto be manipulated easily by a user.
 10. A reusable support deviceaccording to claim 9, wherein the handle is formed by a bent part of thesupport plate.
 11. A reusable support device according to claim 9,wherein the handle is U-shaped.
 12. A reusable support device accordingto claim 9, wherein the handle is at one end of the device.
 13. Areusable support device according to claim 1 including means adapted tolever the support plate, and hence the device, from a fixed panel towhich the support plate is temporarily attached.
 14. A reusable supportdevice according to claim 13, wherein said levering means comprises anextension of the support plate, which extension protrudes from thesupport plate.
 15. A reusable support device according to claim 14,wherein the extension protrudes from an end of the device.
 16. Areusable support device according to claim 15, wherein the extensionprotrudes from the end of the device remote from a U-shaped portion of ahandle of the device.
 17. A reusable support device according to claim1, wherein the device is constructed from metal sheet.
 18. A reusablesupport device according to claim 1, wherein the device is constructedfrom plastics material.
 19. A reusable support device according to claim1, wherein the device is formed from an extrusion.
 20. A reusablesupport device according to claim 1, wherein the device is molded.
 21. Areusable support device according to claim 1, adapted for assisting insupporting plasterboard panels on walls, ceilings or soffits.
 22. Areusable support device according to claim 11, adapted for assisting insupporting a rigid sheet material.
 23. A method of temporarilysupporting a second panel in a common plane and in edge-to-edgerelationship with a fixed panel using a reusable support deviceaccording to claim 1, which method comprises:bringing the flange intoabutment with an edge of the fixed panel, to align the support platewith respect thereto so that the support plate protrudes from the edgeof the fixed panel; temporarily attaching the support plate to the fixedpanel from said one common side; bringing an edge of the second panelinto abutment with the flange to support the second panel in saidrelationship with the fixed panel; and detaching the support plate, andhence the device, from the fixed panel after securing the second panelby other means in said relationship.
 24. An installation for temporarilysupporting a second panel in a common plane and in edge-to-edgerelationship with a fixed panel for subsequent permanent securement ofthe panels in said relationship, the installation comprising:a frameworkmember attached to a structure; a fixed panel secured to the frameworkmember with an edge of the fixed panel extending longitudinally of theframework member between opposed longitudinal edges thereof; a reusablesupport device according to claim 1, which device has its support platetemporarily attached to the fixed panel with its flange abutting an edgeof the fixed panel, such that the support plate of the device is alignedwith respect to the fixed panel, whereby the support plate extendsbeyond said edge of the fixed panel; and a second panel which issupported by the support plate extending beyond said edge of the fixedpanel and which has an edge abutting the flange of the support device,whereby said panels lie in a common plane and in edge-to-edgerelationship with each other with the flange protruding between thepanels not more then thickness of the panels; wherein the support plateof the support device is adapted to be removed from the fixed panel forreuse of the device after the second panel has been secured permanentlyto the framework member in said relationship with the fixed panel. 25.An installation according to claim 24, wherein the support plate of thereusable support device is also removably attached to the frameworkmember through the fixed panel.